Catalytic hydroconversion of carbonaceous materials

Description

Background of the Invention

[0001] This invention relates to an improved process for hydroconverting non-gaseous carbonaceous materials to lower molecular weight products. More particularly, this invention relates to an improved catalytic process for hydroconverting non-gaseous carbonaceous materials to lower molecular weight products.

[0002] Heretofore, several catalytic processes for hydroconverting solid carbonaceous materials, such as coal, lignite, peat and the like, to lower molecular weight products and for converting heavier petroleum fractions, such as atmospheric and vacuum residuals, to lower molecular weight products have been proposed. The lower molecular weight products may be gaseous or liquid or a mixture of both. In general, the production of liquid products is particularly desirable since liquid products are more readily stored and transported and the lower molecular weight liquid products are conveniently used as motor fuels.

[0003] Heretofore, a large number of suitable catalysts have been identified as useful in such hydroconversion processes. For example, metal sulfides and oxides and mixtures thereof have been particularly useful as catalysts in such processes. Moreover, a host of catalyst precursors; that is, compounds that will either decompose or are readily converted to an active sulfide or oxide form have been identified. Such precursors include transition metal complexes, such as transition metal naphthenates, heteropolyacids and ammonium salts of various anions containing one or more transition metals. In general, the precursors used have either been soluble, to some extent, in the reaction medium itself or in a solvent which is added to the reaction medium. The solvents heretofore employed have been both organic and inorganic.

[0004] As is well known in the prior art, the effectiveness of the transition metal sulfide and oxide catalysts has been limited by their respective solubilities at atmospheric conditions or upon heating in the reaction medium itself or in the solvent used to incorporate the same into the reaction media. While the reason or reasons for this limitation on catalytic activity are not well known, it is believed to be due either to the particular size of the active catalyst species ultimately formed in the reaction media or as a result of poor distribution of the active catalyst species within the reaction mixture. Moreover, most, if not all, of the precursor species proposed heretofore require a treatment of some kind with a sulfur compound before the more active sulfide catalyst species is ultimately obtained.

Summary of the Invention

[0005] It has now been discovered that the foregoing and other disadvantages of the prior art catalytic processes can be avoided, or at least reduced, with the method of the present invention and an improved process for converting non-gaseous carbonaceous materials to lower molecular weight products provided thereby. It is, therefore, an object of this invention to provide an improved catalytic process for the conversion of non-gaseous carbonaceous materials to lower molecular weight products, particularly a process wherein the active catalyst species formed is either relatively small or at least is more uniformly distributed, thereby yielding increased conversions.

[0006] The present invention provides a process for hydroconverting non-gaseous carbonaceous materials characterized by comprising:

(a) forming a mixture of a non-gaseous carbonaceous material and a monohydrocarbyl substituted dithiocarbamate of a metal selected from Group VIII-A of the Periodic Table of Elements, or mixture thereof, with or without a suitable solvent or diluent;

(b) subjecting this mixture to hydroconversion conditions; and

(c) recovering a lower molecular weight product from the conversion effluent.

[0007] Thus, in accordance with the present invention, the foregoing and other objects and advantages are accomplished by converting a non-gaseous carbonaceous material to lower molecular weight products in the presence of a catalyst believed to be a metal sulfide or a mixture of such sulfides of a metal from Group VIII-A of the Periodic Table of Elements formed either prior to or during the conversion process through the decomposition of a metal monohydrocarbyl substituted dithiocarbamate or from a mixture of such dithiocarbamates in the presence of molecular hydrogen at an elevated temperature and pressure. As pointed out more fully hereinafter, the total conversion of the carbonaceous material to lower molecular weight products is effected by and can be increased or decreased to some extent through the selection of the catalyst precursor or precursors actually used. As also indicated more fully hereinafter, the various precursors useful in this invention have varying decomposition temperatures and this temperature (or temperatures) is believed to be correlated with the activity of the catalyst specie or species formed.

Brief Description of the Drawing

[0008] The figure is a schematic flow diagram of a process within the scope of the present invention.

Detailed Description of the Invention

[0009] As indicated supra, the present invention relates to an improved catalytic process for converting non-gaseous carbonaceous materials to lower molecular weight products wherein a monohydrocarbyl substituted dithiocarbamate of a metal selected from Group VIII-A of the Periodic Table of Elements or a mixture of such compounds is used as a catalyst precursor (which compounds shall hereinafter be referred to generically as monohydrocarbyl substituted dithiocarbamates of a metal). As also indicated, supra, the conversion of the carbonaceous material will take place in the presence of molecular hydrogen at an elevated temperature and pressure. As further indicated previously, and as will be described more fully, hereinafter, it is believed that the relative activity of the metal sulfide or mixtures thereof formed from the precursor can be increased or decreased by decreasing or increasing, respectively, the temperature at which the precursor or precursors is or can be converted to an active catalyst form. One way of controlling the temperature at which the precursor can be converted to an active catalyst form is through the selection of the precursor.

[0010] In general, the method of the present invention can be used to convert any non-gaseous carbonaceous material composition to lower molecular weight products. The carbonaceous material may then be either normally solid or normally liquid and may be either solid or liquid at conversion conditions. Suitable normally solid carbonaceous materials include, but are not necessarily limited to, coal, trash, biomass, coke, tar sand, petroleum residuals and the like. This invention is particularly useful in the catalytic liquefaction of coal and may be used to liquefy any of the coals known in the prior art, including bituminous coal, subbituminous coal, lignite, peat, brown coal and the like. These materials are, at least initially, solid at conversion conditions. Suitable carbonaceous materials which may be normally liquid include, but are not necessarily limited to, materials remaining after a crude oil has been processed to separate lower boiling constituents, such as atmospheric and vacuum petroleum residuals. In general, petroleum residuals will have an initial boiling point within the range from about 650°F to about 1,150°F. The petroleum residuals will, in all cases, be liquid at the conditions used to effect the catalytic conversion in the improved process of this invention. The improved process of this invention is also particularly applicable to the conversion of bottoms from a vacuum distillation column having an initial boiling point within the range of from about 850°F (343.3°C) to about 1,050°F (565.6°C).

[0011] In general, and when a carbonaceous material which is solid at the conversion conditions is converted in the improved process of this invention, the same will be ground to a finely divided state. The particular particle size or particle size range actually employed, however, is not critical to the invention and, indeed, essentially any particle size can be employed. Notwithstanding this, generally, the solid carbonaceous material which may be liquefied in accordance with this invention will be ground to a particle size of less than inch (6.35 mm) and preferably to a particle size of less than about 8 mesh (M.B.S. sieve size). In the improved process of the present invention and when a petroleum residual is converted the petroleum residual may be combined with a solvent or diluent but the use of a solvent is not critical or essential and, indeed, the catalyst may be added directly to the petroleum residual. When this is done, however, it may be necessary to heat and stir the petroleum residual to insure good dispersion of the catalyst precursor in the petroleum residual.

[0012] The catalyst precursors useful in the improved process of the present invention are monohydrocarbyl substituted dithiocarbamates of metals having the general formula:

wherein R is a hydrocarbyl radical selected from the group consisting of C₁-C₁₈ alkyl radicals; C₅-C_e cycloalkyl radicals; or C_a-C₁₈ alkyl substituted cycloalkyl radicals; or an aromatic or alkyl substituted aromatic radical containing 6 to 18 carbon atoms; M is a metal selected from Group VIII-A of the Periodic Table of Elements as published by Sargent-Welch Scientific Company, 1979; and n is the valence of the metal and will be a number from 2 to 6.

[0013] The precursors useful in the improved process of the present invention are oil soluble at least in the concentration used in the present process at the conditions employed for combining the catalyst with a carbonaceous material and are, generally, thermally decomposable to the corresponding metal sulfide at conditions milder than those used to effect the hydroconversion of the carbonaceous material. Since each of these compounds contain at least enough sulfur to form the corresponding sulfide and since this is the normal decomposition product of the precursor at the conditions used for forming the active catalyst and/ or the conditions used during the conversion of the carbonaceous material, a separate sulfur treatment is not necessary or essential to the formation of the catalytically active sulfide species.

[0014] Some of the monohydrocarbyl substituted metal dithiocarbamates useful as catalyst precursors in the process of the present invention may be available commercially in the United States. Moreover, all can be prepared by any of the standard methods known in the prior art. One such standard method is as follows:



wherein R is a hydrocarbyl radical as identified above; M is a metal as identified above; and X is CI-, Br-, _N03-, _CH3CO2 , S0₄=' etc.

[0015] In general, the catalyst will be added to or combined with the carbonaceous material at a concentration within the range from about 10 ppm to about 10,000 ppm, by weight, of Group VIII-A metal, based on dry, ash-free (DAF) carbonaceous material. The catalyst precursor may be added to a solvent and then combined with a carbonaceous material when a solvent is employed or the catalyst precursor may be added or combined with the carbonaceous material and then the solvent. When a solvent is not used, particularly with a petroleum residual, the catalyst precursor will be combined directly with the petroleum residual.

[0016] After the catalyst precursor or a mixture thereof has been combined with the carbonaceous material the same will be converted to an active catalyst species and particularly to the corresponding sulfide or mixture of sulfides by heating the combination of carbonaceous material and catalyst precursor or precursors either in the presence or absence of a solvent to a temperature at which the monohydrocarbyl substituted dithiocarbamate is converted to the corresponding sulfide as a result of the sulfur already contained in the dithiocarbamate. While the actual temperature or temperatures at which the conversion from dithiocarbamate to sulfide occurs will vary depending upon the metal ion and the hydrocarbyl radical or radicals contained in the dithiocarbamate, the conversion will, generally, occur at a temperature within the range of from about 150°F (65.6°C) to about 625°F (329.4°C).

[0017] While the inventors do not wish to be bound by any particular theory and, as indicated previously, it is believed that the relative catalyst activity and the resulting conversion will vary with the particular hydrocarbyl radical or radicals and the metal or metals contained in the precursor or precursors. This variance in activity appears to vary with the temperature at which the dithiocarbamate is converted to the corresponding sulfide. In this regard, it should be noted that precursors having lower decomposition temperatures tend to lead to the formation of catalytically active species which are more active (or more uniformly distributed in the reaction media) than do precursors having higher decomposition temperatures. Moreover, and while monohydrocarbyl substituted dithiocarbamates are surprisingly more active than the corresponding dihydrocarbyl substituted dithiocarbamates, this is believed to be due to or at least associated with a lower decomposition temperature.

[0018] While a separate conversion step of the precursor or a mixture thereof to an active catalyst form is contemplated in the improved process of the present invention, such a separate conversion is generally not necessary. This is particularly true since overall conversions resulting from the conversion of the precursor during heat-up to the conversion temperature are generally acceptable. A separate conversion step may be used, however, when relatively low temperature conversion of the precursor is desirable. When a separate conversion step is employed the precursor will, generally, be decomposed to the corresponding sulfide in an inert atmosphere and in the absence of hydrogen, but may be completed in the presence of H₂S.

[0019] After the mixture of catalyst precursor and carbonaceous material has been prepared, either with or without a solvent, and the precursor converted to an active catalyst form, when a separate decomposition step is used or during heat-up of the mixture when a separate decomposition is not used, the mixture will be passed to a carbonaceous material conversion zone and at least a portion of the carbonaceous material material will be converted to lower molecular weight products in the presence of hydrogen. In general, conversion of the carbonaceous material will be accomplished at a temperature within the range of from about 500°F (260°C) to about 1,000°F (537.8°C) and at a total (gauge or indicated) pressure within the range from about 500 psig (3.448 MPa) to about 7,000 psig (48.265 MPa). Molecular hydrogen will be present during the conversion at a partial pressure within the range of from about 400 to about 5,000 psig (2.75 to 34.475 MPa). In general, the conversion of the carbonaceous material may be accomplished either in a single stage or in a plurality of stages. In any case, the total nominal holding time at conversion conditions will, generally, range from about 10 minutes to about 600 minutes. Moreover, and while significant conversions will be realized when catalyst concentration is maintained within the aforementioned range (10 ppm to 10,000 ppm, by weight Group VIII-A metal based on carbonaceous feed material, DAF^*) on a once-through basis, the catalyst concentration, and hence catalytic activity in any stage or stages, can be increased by recycling bottoms material containing active catalyst species to said stage or stages.

[0020] In general, the conversion of the carbonaceous material to lower molecular weight products results in the production of a normally gaseous product, a normally liquid product and a bottoms product which will have characteristics similar to or identical to those of the feed material. In this regard, it should be noted that when the carbonaceous material is a normally solid material the bottoms product will be normally solid. When the carbonaceous material is a petroleum residual, on the other hand, the bottoms product may be just a high boiling liquid or semi-liquid product. As used herein, the recitation "normally" means at atmospheric conditions. After the conversion of the carbonaceous material is completed the several products may be separated into their respective phases using conventional techniques. The catalyst, in some form, will generally be contained in the bottoms product.

[0021] In general, and when a plurality of conversion stages or zones are employed, the gaseous and lighter boiling liquid hydrocarbons will, generally, be separated beween each stage. Normally, this separation will include all components having a boiling pont below about 350 to about 450°F (176.7 to 232.2°C). Moreover, after the lower boiling point materials have been separated, a portion of the remaining slurry could be recycled to any previous stage to increase the total conversion and the catalyst concentration in said stage. When a single conversion stage or zone is employed or after the final stage when a plurality of conversion stages or zones is used, the product from the conversion will be separated into at least three product streams. Moreover, in those operations wherein a solvent is used this solvent, generally, will be separated from the normally liquid product. In this regard, it should be noted that when the carbonaceous material is a solid and particularly coal, lignite, peat or the like, the solvent fraction will, preferably, have an initial boiling point within the range from about 350 to about 650°F (176.7 and 343.3°C) and a final boiling point within the range of from about 700 to about 1,100°F (371.1 to 593.3°C). When a solvent is used with a petroleum residual, on the other hand, a heavier solvent will generally be used and this solvent will, preferably, have an initial boiling point within the range from about 650°F (343.3°C) to about 800°F (426.7°C) and a final boiling point within the range from about 800°F to about 1,100°F (426.7°C and 593.3°C).

[0022] As indicated previously, the metal constituents of the dithiocarbamate precursors useful in the process of this invention will be selected from the group consisting of Group VIII-A of the Periodic Table of Elements, published by Sargent-Welch Scientific Company, and mixtures thereof. The Group VIII-A metals consist of the iron group metals; viz, iron, cobalt, nickel and the noble metals; viz, platinum, iridium, palladium, osmium, ruthenium and rhodium. The preferred metal constituent in the catalyst precursors useful in the present invention will be selected from the iron group of metals; viz, iron, nickel and cobalt. Most preferably, the metal constituent will be nickel.

[0023] After the carbonaceous material conversion is completed and the several products separated the gaseous product may be upgraded to a pipeline gas, a high purity synthesis gas, or the same may be burned to provide energy for the conversion process. Alternatively, all or any portion of the gaseous product may be reformed to provide hydrogen for the liquefaction process.

[0024] The liquid product may be fractionated into essentially any desired product distribution and/or a portion thereof may also be used directly as a fuel or upgraded using conventional techniques. Generally, a naphtha boiling range fraction will be recovered and the naphtha fraction will be further processed to yield a high quality motor gasoline or similar fuel boiling in the naphtha range. Also, a middle distillate fraction may be separated from the liquid product and upgraded for use as a fuel oil or a diesel oil.

[0025] The bottoms product may be gasified, depending upon its carbon content, to produce hydrogen for the conversion process or burned to provide heat for the conversion process. In the case of relatively high conversion, however, and when the carbon content is too low to make either gasification or combustion feasible, the bottoms product may simply be disposed of as waste material. In this case, all or a portion of the catalyst may be recovered in either an active or inactive form.

Preferred Embodiment

[0026] In a preferred embodiment of the improved process of the present invention a monoalkyl substituted dithiocarbamate or an iron group metal, viz, iron, nickel and cobalt, wherein the alkyl group (R in the general formula, supra) contains from 1 to 10 carbon atoms will be used. In a most preferred embodiment of the improved process of the present invention the Group VIII-A metal will be nickel. Also, in a preferred embodiment the monohydrocarbyl substituted dithiocarbamate of a metal will be converted to the corresponding metal sulfide during heat-up of the precursor to the conditions employed in the carbonaceous material conversion stage or zone. Still, in a preferred embodiment of the improved process of the present invention, the carbonaceous material will be converted at an average conversion temperature within the range from about 700 to about 870°F (371.1 to 465.6°C), most preferably 750 to 860°F (398.9 to 460°C), in the presence of molecular hydrogen at a partial pressure within the range from about 1,000 to about 1,800 psig (6.895 to 12.411 MPa), most preferably 1,200 to 1,600 psig (8.274 to 11.032 MPa), and at a total (indicated or gauge) presure within the range from about 800 to about 3,000 psig (5.516 to 20.685 MPa), most preferably 1,500 to 2,500 psig (10.343 to 17.238 MPa).
^* "DAF" is an abbreviation for "dry and ash-free"

[0027] While the improved process of the present invention may be practiced in either a batch or continuous operation and with either a single conversion zone or with a plurality of conversion zones, the improved process of this invention will, preferably, be practiced continuously in a single stage operation. Moreover, in a preferred embodiment of the present invention a solvent will be employed and the catalyst precursor will be combined with the solvent prior to combining the solvent with the carbonaceous material. In a preferred embodiment the catalyst concentration will be within the range from about 50 to about 2,000 ppm of Group VIII-A metal on a weight basis, based on dry, ash-free carbonaceous material, and, in a most preferred embodiment, the catalyst concentration will be within the range from about 100 to about 1,000 ppm of a Group VIII-A metal on a weight basis, based on dry, ash-free carbonaceous material. In a most preferred embodiment of the present invention the hydrocarbyl substituted dithiocarbamate of a metal will be used to convert a solid carbonaceous material, particularly coal, lignite, peat and the like.

[0028] A single stage embodiment of the present invention is illustrated in the attached Figure and it is believed that the invention will be better understood by reference to this Figure. Referring then to the Figure, a carbonaceous material is introduced into preparation vessel 110 through line 111. As indicated, supra, the carbonaceous material may be either normally solid or normally liquid. When the carbonaceous material is solid at the conditions at which it is introduced into preparation vessel 110 the carbonaceous material will be finely divided. In the preparation vessel the carbonaceous material is combined with a monohydrocarbyl substituted dithiocarbamate of a metal which, as indicated previously, serves as a catalyst precursor, which catalyst precursor is introduced through line 112.

[0029] In a preferred embodiment and when the catalyst precursor has been previously combined with a solvent or diluent the precursor-solvent may be combined in a suitable mixing vessel, such as 113. In the embodiment illustrated a suitable solvent may be introduced into mixing vessel 113 through line 114 while the catalyst precursor is introduced into mixing vessel 113 through line 115. Generally, agitating means, such as agitator 116, will be provided in mixing vessel 113. The mixing vessel may be operated at any suitable temperature below the precursor decomposition temperature to insure that the catalyst precursor is dissolved in the solvent as the mixture is withdrawn through line 117 and passed into line 112. When a solvent is not employed or when the catalyst precursor and solvent are not premixed, the precursor may be fed directly into line 112 from line 115 through line 118. In those embodiments wherein a solvent is used but not combined with a catalyst precursor prior to introduction into preparation vessel 110 a suitable solvent may be introduced through line 119.

[0030] To insure the preparation of a relatively uniform mixture of carbonaceous material catalyst precursor (and solvent, when a solvent is employed) preparation vessel 110 may comprise a suitable agitation means, such as agitator 120. Generally, the preparation vessel 110 will be operated at conditions suitable for the preparation of a satisfactory mixture and, in any case, at a temperature sufficient to insure that the catalyst precursor remains dissolved in the solvent or, when a solvent is not employed, in the carbonaceous material.

[0031] After the mixture of carbonaceous material, catalyst precursor (and solvent, when a solvent is employed) is prepared the same will be withdrawn from the preparation vessel through line 121. The mixture will then be heated to a temperature at or near conversion temperature by passing the same through preheater 122. The mixture is then withdrawn through line 123 and, when a carbonaceous material containing water has been used, the mixture may be passed to flash drum 124 wherein at least a portion of water, as steam, may be flashed overhead through line 125 and a mixture suitable for conversion withdrawn through line 126. The mixture is then fed to conversion stage or zone 127 and is combined with molecular hydrogen added through line 128.

[0032] In the conversion zone 127 the carbonaceous material will be converted, at least in part, to lighter molecular weight products. The conversion will, generally, be achieved at a temperature within the range from about 500 to about 900°F (260 to 482.2°C) and at a total (gauge or indicated) pressure within the range from about 500 to about 7,000 psig (3.448 to 48.265 MPa) and with a hydrogen partial pressure within the range of from about 400 to about 5,000 psig (2.758 to 34.475 MPa). In a preferred embodiment the conversion will be achieved at a temperature within the range of from about 700 to about 870°F (371.1 to 465.6°C), at a total (indicated or gauge) pressure within the range from about 800 to about 3,000 psig (5.516 to 20.685 MPa) and at a hydrogen partial pressure within the range from about 1,000 to about 1,800 psig (6.895 to 12.411 MPa). In a most preferred embodiment of the present invention the conversion will be accomplished at a temperature within the range from about 750°F to about 860°F (398.9 to 460°C), at a total (indicated or gauge) pressure within the range from about 1,500 psig to about 2,500 psig (10.34 to 17.238 MPa), and a hydrogen partial pressure within the range from about 1,200 psig to about 1,600 psig (8.274 to 11.032 MPa). Gaseous products and any unconsumed hydrogen may be withdrawn from the conversion zone through line 129. The conversion products, except any that may be withdrawn through line 129 and any unreacted feed (and spent solvent, when a solvent is employed) will be withdrawn from the conversion zone 127 through line 130.

[0033] The effluent from conversion stage or zone 127 withdrawn through line 130 is then fed to a suitable separator 131. The separator may consist of any suitable means for separating the effluent into its various fractions, such as a gaseous fraction, a liquid fraction, and a bottoms fraction which, when a solid carbonaceous material is converted, will be normally solid. Suitable separation devices include, but are not necessarily limited to, knock-out pots, which may be used alone or in combination with filters, centrifuges, distillation apparatus and the like. In a preferred embodiment, and particularly when a solid carbonaceous material is converted, the separation means will be a distillation column comprising an atmospheric and vacuum fractionation column. When such a distillation apparatus is employed a normally gaseous product may be withdrawn overhead through line 132. Similarly, a bottoms product, which may be normally solid and include unconverted feed, catalyst and ash, may be withdrawn through line 133.

[0034] The normally liquid product may then be separated into fractions having any desired boiling range or ranges. For example a relatively light product boiling, generally, within the naphtha range may be withdrawn through line 134. A heavier boiling fraction, for example, a fraction having an initial boiling point within the range from about 350 to about 650°F (176.7 to 343.3°C) and a final boiling point within the range from about 700 to about 1,100°F (371.1 to 593.3°C) may be withdrawn through line 135 and a still higher boiling fraction, for example, a fraction having an initial boiling point within the range from about 650 to about 800°F (343.3 to 426.7°C) and a final boiling point within the range from about 800 to about 1,100°F (426.7 to 593.3°C) may be withdrawn through line 136.

[0035] In a preferred embodiment and when a solid carbonaceous material is converted, particularly coal, lignite, peat and the like, at least a portion of the material having an initial boiling point within the range from about 350 to about 650°F (176.7 to 343.3°C) and a final boiling point within the range from about 700 to about 1,100°F (371.1 to 593.3°C) will be recycled and used as a solvent. The recycle may be accomplished through lines 135-135, where the recycle solvent would be introduced into mixing vessel 113 through line 114. When recycled solvent is not, however, used or when the amount of recycle solvent available is not sufficient, extraneous solvent may be introduced into line 114 through line 137. In those cases where the amount of solvent boiling range material is in excess of needs the excess may be withdrawn through line 138.

[0036] While not illustrated and as indicated, supra, when a petroleum residual is converted in accordance with the process of this invention and when a solvent is employed at least a portion of the higher fraction withdrawn through line 136 would normally be recycled and used as recycle solvent.

[0037] Any stream ultimately withdrawn from the separator may be used directly for many purposes as a final product or any or all of the streams may be further upgraded to yield products of enhanced value. For example, the gaseous stream withdrawn in line 129 and overhead through line 132 may be combined, scrubbed to separate pollutants and other non-combustible materials and treated to separate molecular hydrogen so as to yield a pipeline quality gas. Similarly, the lighter boiling fraction withdrawn through line 134, which boils in the motor gasoline range, may be further upgraded to yield a high quality gasoline. A fraction boiling in the middle distillate range may be further treated to yield a middle distillate fuel oil and, in some cases, to yield a diesel fuel. The heaviest boiling fraction withdrawn through line 136 may also be further treated to yield a satisfactory vacuum gas oil which may also be used as a fuel. The bottoms product withdrawn through line 133 may be burned directly to recover its fuel value or the same may be discarded, directly, especially in those cases where the carbon content is too low to support combustion.

[0038] As indicated previously, all or a part of the catalyst species may be separated from the bottoms stream prior to discarding the same. Moreover, a portion of this bottoms stream could be recycled to the conversion zone 127 to increase the concentration of catalyst therein, thereby increasing the total conversion of carbonaceous material during the conversion step and reducing the amount of catalyst precursor added initially.

[0039] Having thus broadly described the present invention and a preferred and most preferred embodiment thereof, it is believed that the same will become even more apparent by reference to the following Examples. It will be appreciated, however, that the examples are presented solely for purposes of illustration and should not be construed as limiting the invention.

Example 1

[0040] In this Example a series of four coal liquefaction runs were completed in tubing bombs. In each run 3 grams of a Wyoming subbituminous coal (Wyodak mine) and 4.8 grams of a hydrogen donor solvent obtained from a coal liquefaction recycle stream and containing 400-700°F (204.4 to 371.1°C) material and a 1.2 weight percent donatable hydrogen were placed in 35 milliliter stainless steel high pressure bath reactors (tubing bombs). In one run no catalyst or catalyst precursor was used. In the remaining three runs a monobutyl substituted catalyst precursor within the scope of this invention was used. The exact catalyst precursor used in each run is identified in Table I. In each run in which a catalyst precursor was added the transition metal dithiocarbamate catalyst precursor was first mixed with the solvent. All catalyst precursors were added at a concentration of 1,000 ppm metal on dry coal. The system was pressurized to 1,000 psig (6.895 indicated pressure) hydrogen at room temperature (5―6 weight percent hydrogen on dry coal). This results in a system (indicated or gauge) pressure of about 2,400 psig (16.548 MPa) at reaction conditions. The reactor was heated to 840°F (448.9°C) by immersion in a fluidized sand bath. Agitation was supplied by a pneumatic agitator operating at 2 cycles per second. Reaction was carried out for 60 minutes. Temperature and pressure profiles were obtained for each run.

[0041] After reaction the reactor was cooled to room temperature. The gases were collected and analyzed by gas chromatography. The slurry in the reactor was extracted with cyclohexane four times and the residue was dried at 110°C for 24 hours. Conversion was defined as 100-100 x (gram of insoluble material/gram of coal) on a weight percent dry coal basis. Percent liquid yield (C₄-1,000°F liquids, including water) was calculated as percent conversion - percent gas + percent H₂ consumption. The results obtained in this series of runs are shown in Table I.

Example 2

[0042] In this Example a series of three coal liquefaction runs were completed in a manner identical to that described in Example 1, except that a dibutyl substituted dithiocarbamate was added and used as the catalyst precursor. The exact catalyst precursor is identified in Table 1 and the results obtained as summarized in said Table I to facilitate a direct comparison thereof.

Example 3

[0043] In this Example five coal liquefaction runs were completed in an autoclave. In each run 40.0 grams of a Wyoming subbituminous coal (Wyodak mine) and 64.0 grams of donor hydrogen solvent were placed in 300 milliliter stainless steel autoclaves equipped with magnetically driven stirrers. The solvent was the same as that described in Example 1. In one run no catalyst or catalyst precursor was added. In another run a monobutyl nickel dithiocarbamate, a catalyst precursor within the scope of the present invention, was used as a catalyst precursor. In still another run, a monooctyl nickel dithiocarbamate, a catalyst precursor also within the scope of the present invention, was used as a catalyst precursor. In the remaining two runs a dialkyl nickel dithiocarbamate was used as a catalyst precursor. The actual catalyst precursor and the conditions used in each run are identified in Table II. Hydrogen gas was added to the autoclave as needed to maintain the specified pressure.

[0044] As will be apparent from an examination of the results summarized in Tables I and II, the monohydrocarbyl substituted metal dithiocarbamates are significantly more active and their use results in an increased yield of liquid product and a corresponding decrease in the yield of gaseous product (C_l-C₃). Moreover, the monooctyl nickel dithiocarbamate is significantly more active than the dibutyl nickel dithiocarbamate even though both have eight carbon atoms in the hydrocarbyl substitution.

[0045] While the present invention has been described and illustrated by reference to particular embodiments thereof, it will be appreciated by those of ordinary skill in the art that the same lends itself to variations not necessarily illustrated herein. For this reason, then, reference should be made solely to the appended claims for purposes of determining the true scope of the present invention.

Claims

1. A process for hydroconverting non-gaseous carbonaceous materials characterized by comprising:

(a) forming a mixture of a non-gaseous carbonaceous material and a monohydrocarbyl substituted dithiocarbamate of a metal selected from Group VIII-A of the Periodic Table of Elements, or mixture thereof, with or without a suitable solvent or diluent;

(b) subjecting this mixture to hydroconversion conditions; and

(c) recovering a lower molecular weight product from the conversion effluent.

2. A process according to claim 1 further characterized in that said carbonaceous material is a petroleum residual or a normally solid carbonaceous material.

3. A process according to claim 2 further characterized in that said normally solid hydrocarbonaceous material is selected from the group consisting of coal, lignite and peat.

4. A process according to any one of claims 1-3 further characterized in that said metal is selected from the group consisting of iron, nickel and cobalt.

5. A process according to any of claims 1-4 further characterized in that the hydroconversion is accomplished at a temperature within the range from about 260 to about 482°C (about 500 to about 900°F), at a total pressure within the range from about 3.45 x 10³ kPa to about 4.83 x 10° kPa (about 500 to about 7,000 psig) and with a hydrogen partial pressure within the range from about 2.76 x 10³ kPa to about 3.45 x 10⁴ kPa (about 400 to about 5,000 psig).

6. A process according to any one of claims 1-5 further characterized in that a sufficient amount of the said monohydrocarbyl substituted dithiocarbamate(s) is added to said mixture to provide from about 10 to about 10,000, preferably 50 to 2000, ppm metal by weight based on carbonaceous material during the hydroconversion step.

7. A process according to any preceding claim, wherein at least a portion of bottoms material from the hydroconversion is recycled to decrease the amount of fresh said dithiocarbamate required.

8. A process according to any one of claims 1-7 further characterized in that the monohydrocarbyl substitution is a hydrocarbyl radical selected from the group consisting of C_l-C_la alkyl radicals; C_S-C₈ cycloalkyl radicals; or Ca-C18 alkyl substituted cycloalkyl radicals or an aromatic or alkyl substituted aromatic radical containing 6 to 18 carbon atoms.

Ansprüche

1. Verfahren zur Hydrokonvertierung von nicht-gasförmigen kohlenstoffhaltigen Materialien, gekennzeichnet durch:

(a) Bildung einer Mischung aus einem nicht-gasförmigen kohlenstoffhaltigen Material und einem monohydrocarbyl-substituierten Dithiocarbamat eines Metalls, ausgewählt aus der Gruppe VIII-A des periodischen Systems der Elemente oder eine Mischung davon, mit einem geeigneten Lösungsmittel oder Verdünnungsmittel oder ohne ein derartiges Lösungsmittel oder Verdünnungsmittel,

(b) Unterwerfung dieer Mischung unter Hydrokonvertierungsbedingungen und

(c) Gewinnung eines niedermolekularen Produkts aus dem Konvertiserungsabfluß.

2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das kohlenstoffhaltige Material ein Erdölrückstand oder eine normalerweise festes kohlenstoffhaltiges Material ist.

3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß das normalerweise feste kohlenstoffhaltige Material ausgewählt ist aus der Gruppe bestehend aus Kohle, Lignit und Torf.

4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß das Metall ausgewählt ist aus der Gruppe bestehend aus Eisen, Nickel und Kobalt.

5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß die Hydrokonvertierung bei einer Temperatur im Bereich von etwa 260 bis 482°C, einem Gesamtdruck im Beeich von etwa 3,45 x 10³ kPa bis etwa 4,83 x 10⁴ kPa und einem Wasserstoffpartialdruck im Bereich von etwa 2,76 x 10³ kPa bis etwa 3,45 x 10⁴ kPa durchgeführt wird.

6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, daß eine ausreichende Menge des (der) monohydrocarbylsubstituierten Dithiocarbamats (Dithiocarbamate) zu der Mischung gegeben wird, um etwa 10 bis etwa 10 000, vorzugsweise 50 bis 2000 Gew.-ppm Metall bezogen auf das kohlenstoffhaltige Material während der Hydrokonvertierungsstufe zu liefern.

7. Verfahren nach einem der vorangehenden Ansprüche, bei dem mindestens ein Teil des Bodenmaterials aus der Hydrokonvertierung zurückgeführt wird, um die erforderliche Menge an frischem Dithiocarbamat zu verringern.

8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß die Monohydrocarbylsubstitution ein Hydrocarbylrest ausgewählt aus der Gruppe bestehend aus C₁―C₁₈-Alkylresten, C₅―C₈-Cycloalkylresten oder C₆―C₁₈-alkylsubstituierten Cycloalkylresten oder einem aromatischen oder alkylsubstituierten aromatischen Rest mit 6 bis 18 Kohlenstoffatomen ausgewählt ist.

Revendications

1. Procédé d'hydroconversion de matières carbonées non gazeuses, caractérisé en ce qu'il comprend:

(a) former un mélange d'un matériau carboné non gazeux et d'un dithiocarbamate, monohydrocarbylsubstitué, d'un métal choisi dans le groupe VIII-A du Tableau Périodique des Eléments, ou d'un de leurs mélanges, avec ou sans un solvant ou un diluant approprié;

(b) soumettre ce mélange à des conditions d'hydroconversion; et

(c) récupérer de l'effluent de la conversion un produit à faible masse moléculaire.

2. Procédé selon la revendication 1, caractérisé en ce que ledit matériau carboné est un résidu pétrolier ou un matériau carboné normalement solide.

3. Procédé selon la revendication 2, caractérisé en ce que ledit matériau carboné normalement solide est choisi dans l'ensemble comprenant le charbon, la lignite et la tourbe.

4. Procédé selon l'une quelconque des revendications 1-3, caractérisé en ce que ledit métal est choisi dans l'ensemble constitué du fer, du nickel et du cobalt.

5. Procédé selon l'une quelconque des revendications 1-4, caractérisé en ce que l'hydroconversion est réalisée à une température d'environ 260 à environ 482°C (d'environ 500 à environ 900°F), sous une pression totale comprise entre environ 3,45.10³ kPa et environ 4,83.10⁴ kPa (entre environ 500 et environ 7000 psig), et sous une pression partielle d'hydrogène comprise entre environ 2,76·10³ kPa et environ 3,45·10⁴ kPa (entre environ 400 et environ 5000 psig).

6. Procédé selon l'une quelconque des revendications 1-5, caractérisé en ce qu'on ajoute audit mélange une quantité du ou de dithiocarbamates monohydrocarbyl-substitués suffisante pour donner d'environ 10 à environ 10 000, de préférence de 50 à 2000 ppm en poids de métal par rapport au matériau carboné pendant l'étape d'hydroconversion.

7. Procédé selon l'une quelconque des revendications précédentes, dans lequel au moins une partie du matériau de fond provenant de l'hydroconversion est recyclée pour diminuer la quantité de dithiocarbamate frais requis.

8. Procédé selon l'une quelconque des revendications 1-7, caractérisé en ce que la substitution par des radicaux monohydrocarbyle utilise des radicaux hydrocarbyle choisis dans l'ensemble consistant en radicaux alkyle en C₁―C₁₈, radicaux cycloalkyle en C₅―C₈ ou encore radicaux cycloalkyle en C₆―C₁₈ alkyl- substitués, ou encore radicaux aromatiques ayant de 6 à 18 atomes de carbone, non substitués ou substitués par des radicaux alkyle.

Drawing